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Fabrication of the second wing for the expedition boat conversion involves welding steel plating onto structural ribs to create a watertight, aerodynamic foil shape. The process requires precise alignment of the steel skins, which are marked, drilled, and slotted using a one-millimeter cutoff disc to ensure a tight, weldable gap.7:47 Structural arms linking the wings to the hull are constructed by laminating three 50mm by 5mm steel sections to achieve 10mm wall thickness for rigidity.5:21 A new TIG welder is utilized for stainless steel components, while a repurposed stainless steel beer keg serves as a sediment-trapping sump for yard wastewater.0:28 After tacking the skin in place, the crew grinds the ribs and plate edges to bare metal to ensure high-quality welds.15:45 The wings are then fully welded, cleaned with a flapper disc, and prepared for pressure testing and the installation of mounting hinges.19:32 A temporary canvas tarpaulin provides weather protection for the outdoor workspace during rain.14:48

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